Maintenance planning for equipment fleets

When you need it

The service is relevant if the company faces:

• frequent unplanned repairs and breakdown stoppages
• missed or late maintenance
• no single schedule for maintenance and repairs
• a large volume of overdue work
• a heavily loaded repair crew while equipment availability stays low
• long waits for spare parts, materials or service resources
• no transparent record of future repair demand
• conflicts between production and repair plans
• no way to forecast the load on workshops and staff in advance
• no common standards for maintenance intervals and scope
• the need to raise fleet availability and reliability

What you get

On completion the client receives:

• a structured register of vehicles and maintained equipment
• maintenance intervals defined for every equipment group
• a list of scheduled works and inspection operations
• annual, monthly and weekly maintenance plans
• a forecast of upcoming maintenance and repairs by running hours and calendar intervals
• a workload plan for the repair crew and workshop capacity
• a list of the tools, materials, spare parts and service resources required
• a way of prioritising repair work
• an approach to managing overdue and unfinished work
• recommendations on building a repair reserve
• a set of key maintenance performance indicators
• recommendations on raising fleet availability and cutting unplanned downtime

Where required, a single maintenance planning model is prepared that can be used in the company ERP, EAM or CMMS system.

How it works

1. We analyse the fleet. We study the equipment mix, models, operating modes, running hours, current maintenance standards, repair and failure history.
2. We build the maintenance structure. We define maintenance types, intervals, mandatory works, inspection operations and the resources required for each equipment group.
3. We analyse the actual workload. We assess the volume of repair work, the availability of staff, workshops, tools and spare parts, and the duration of typical operations.
4. We build the maintenance forecast. Using running hours and calendar intervals we determine when each unit is due for its next service or repair.
5. We draw up the plans. We prepare long term, monthly and weekly plans that take priorities, production load, equipment availability and repair resources into account.
6. We set up execution control. We define the rules for tracking planned work, overdue items, postponed maintenance, unfinished work and deviations from the schedule.
7. We define performance indicators. We build a set of indicators covering availability, planned maintenance compliance, breakdown repairs, backlog and the use of repair resources.

The outcome

The company gets a maintenance system it can steer, where it is known in advance:

• which equipment needs service
• when the work has to be done
• what resources it will take
• which jobs come first
• what risks come with postponing maintenance
• how the current repair plan affects availability across the fleet

This is what makes the move from reactive repair to planned management of technical condition and reliability possible.